“Sustainability: the New Manufacturing Imperative” | |||||
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THE CONFERENCE AT PACK EXPO PROGRAM-AT-A-GLANCE | |||||
WEDNESDAY, OCTOBER 17, 2007 | |||||
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UPGRADING OPERATIONS |
TRACK & TRACE |
SAFETY |
PROCESSING |
CONVERTING |
8:30- |
Competing Globally: Are We Missing Das Boat? Technician Training in Germany |
Effective Recall Strategies Begin with Effective Product Tagging |
Selecting and Implementing a Safety Architecture (Including Networks) to Provide the Most Cost-Effective Solution for Your Packaging Equipment |
A Realistic Approach to Traceability |
Focus for Profits in Converting & Package Printing |
9:20- |
Secrets of Best-In-Class Manufacturing Operations: Based on a Real-Time Benchmark Study of CPG Operations |
RFID—Improved Logistics and Product Tracking |
Tackling Waste and Process Line Inefficiencies by Using Real-Time Process Control |
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10:10-10:50am |
KEYNOTE: | ||||
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COST SAVINGS |
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11:00- |
Robotics - This Is Why It’s Hot |
Automatic RFID Label Application - Keys to Success |
Boost Profits and Sustainability with Optimized Purchasing |
Aseptic Processing: Innovation for Manufacturers, More Options for Consumers |
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11:50am- |
OEE and TEEP—What Do They Mean? Are They Related and What Value Can They Give Me? |
A Cost Analysis of Printing Secondary Packaging vs. Ordering Preprinted Containers |
New Generation of Chemical Dispensing Systems |
Increase Profits by Aligning Your Assets |
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LUNCH |
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The U.S. Food and Drug Administration (FDA) is committed to ensuring that United States’ (U.S.) food supply continues to be among the safest in the world. However, we face significant challenges. While U.S. consumers and businesses benefit from unprecedented global trade, increases in the volume and complexity of imported goods and growing international threats such as terrorism and emerging foodborne diseases have taxed the limits of the FDA approach to handling imports. Another challenge is the significant increase during the past decade in consumption of produce, particularly ready-to-eat products. In response to recent foodborne illness and product contamination, FDA has adopted a farm-to-fork approach to food safety to reduce the risk of foodborne illness at all points in the food chain. This approach systematically applies risk management principles at each step as food moves from growers and producers to consumers. FDA is focusing and renewing its food safety efforts in three key areas: emphasizing the importance of prevention, intervening through inspections and testing to ensure prevention is working and to intercept problems before they cause illness, and developing faster responses. All three of these areas are dependent on strengthening the scientific basis for FDA’s food safety program, enhancing effective partnerships, and improving risk-based targeting of inspection resources. To enhance the safety of all human and animal foods, whether domestic or imported, FDA continues to work closely with Federal, state, local, and international food safety agencies, and with industry, consumers, and academia to develop and implement programs at each point in the supply chain to prevent and minimize contamination.
Description: It can be argued that German maintenance technicians receive more useful educations than our degreed engineers. There, automation technicians study for four years, with fully half their studies spent in practical, hands-on apprenticeships on the plant floor working on real projects with real engineers. They learn IEC automation programming and electronic and mechanical engineering skills. And the best of the best compete to become ”mechatronics” technicians because they know these jobs are in highest demand. Learn what German apprentices study, what we can do to up-skill our packaging workforce and how PMMI members are working behind the scenes to bridge the technical skills gap.
Description: Best-in-class enterprises use manufacturing intelligence to build, accelerate and sustain operational performance and achieve business objectives. They have thorough visibility of key metrics, real-time measurement of those metrics, and they can quantify and understand the financial impacts of change. As a result, they typically increase capacity, reduce inventory, improve cycle time and increase working capital. Their entire workforce – machine operators, plant managers, operations management and enterprise management – can respond to variances and opportunities as they arise, not days or weeks later. Learn what characteristics differentiate best-in-class manufacturers from average and laggard performers, and learn how one best-in-class manufacturer built on their improvement initiative and adapted best-in-class strategies. Results of a CPG Operations Benchmark Study (based on 200 lines worldwide) will be covered in this presentation.
Description: Find out what technological advances in robotics have led to the re-emergence of robotics into high-speed applications, such as beverages and personal care. The presentation focuses on the challenges of rainbow packing.
Description: Today, more and more, the terms “OEE” and “TEEP” are being used and abused. OEE means Overall Equipment Effectiveness and relates to understanding the production process during the scheduled time. TEEP means Total Effective Equipment Productivity and relates to understanding the production process considering all time. This short talk will aim at demystifying these terms and give you a simple road map to use back in your operations to give insight, as well as strategic and tactical value. Simple equations and methods of how to get OEE and TEEP values from rudimentary data will be shown, as well as how to obtain data to drill down to aid in problem-solving and developing solutions.
Description: Blanket recalls can cost unnecessary millions, as some recent headlines on recalls indicate: Sony Battery, $429M; Sanyo Battery, $17M; ConAgra Peanut Butter, $50-60M; Cadbury Schweppes Chocolate, £20M; Menu Foods Pet Food, $40M. These figures do not include critical revenue hits, such as loss of shareholder value, imposed fines, loss of future sales, lawsuits, workforce reductions and cost of disposal. Does your company have enough market strength and brand credibility to recover from an expensive recall? What is your strategy to survive? To initiate “target” recalls, a robust track-and-trace strategy must be in place that details raw materials utilized; when and where products were produced; product quantities and inventory locations; products picked; and products shipped. The key target recall strategy enabler is the marking of finished good items at the unit, packaging, case and pallet levels. How do marked items address your critical recall issues, and what type of vendors and products can aid your track-and-trace strategies? This session will provide advice and give direction.
Description: With increased market awareness, by and large because of the retailers, RFID technology is getting much deserved recognition for value it can provide. Packaging OEMs and end users have the opportunity to understand the RFID value proposition. RFID can have an impact in all markets, not just retail and automotive. Understand how RFID can reduce or eliminate business processes that take profits from the bottom line. RFID is a proven technology with decades of ROI examples. Learn how RFID can help you.
Description: This session covers the basics of label auto-apply systems and then focuses on the additional RFID issues that need to be addressed to find the best system for your company, including how to integrate RFID auto-apply into existing production and conveying lines; the options for incorporating RFID case and pallet tagging in packaging operations; and how current processes and movement of product through the operation affect decisions. In addition, this session will cover issues relating to how to avoid reduced throughput, software and hardware connectivity issues, challenges and lessons learned, label applicator technology, and trends for the future.
Description: This session will explore the use of Contemporary Safety Solutions available in the market today to keep costs under control while providing a safe and competitive design on your packaging machines.
Description: Safety is usually associated with adding cost to the machine. End users struggle with how to make their machines safe, without making the machine too costly to buy. What if the safety technology incorporated on your new machine actually improved your OEE, with minimal cost impact? That’s what drive-based safety technology offers!
Description: Disconnecting corrugated purchasing from the production schedule can save companies tens to hundreds of thousands of dollars. Replacing preprint with a comprehensive generic case printing program puts the power of choice into the hands of the buyer through optimized purchasing and competitive bidding. It also boosts sustainability scores by substantially reducing scrap, obsolescence and recycling and by eliminating printing plates. The case studies and cost models to be presented on the impact of generic case printing will speak directly to anyone involved with private-labeling dozens to hundreds of SKUs. Attendees will also receive an assessment tool to gauge the benefits of a generic case program for their operation.
Description: Product manufacturers are realizing distinct cost advantages when choosing to use large-character ink jet printers to print variable data like bar codes, lot information and even graphics on secondary packaging. Over time, it is less costly to use such printers to mark blank corrugated boxes than buying preprinted boxes that must be reordered. Additionally, today’s large-character printers are able to create more distinctive graphics, which can aid in branding initiatives. The proposed seminar will provide a cost analysis between marking secondary packaging in-house versus preprinted counterparts and provide examples of manufacturers that implemented that strategy and the resultant benefits.
Description: Current events, such as spoiled produce, as well as legislation such as the Bioterrorism Act, make product traceability a top topic. A lot of companies, however, don’t have a realistic approach to this. Many technologies exist that can improve the concepts, but they are also costly and sometimes not very cost-effective. The seminar will include a pragmatic approach to traceability. How would I determine the risk, and how does a recall process practically happen? I will explain how you would go about determining the level of granularity of your traceability system from an economical point of view and which very simple things you can do to enhance the traceability capabilities in your organization.
Description: To stay competitive, food processors today must focus on ways to minimize waste and improve product yield. Many processors experience fluctuating periods of high and low flow rates, causing drastic process inefficiencies and material waste. The proposed presentation will examine how processors can reduce operation inefficiencies with real-time process control, and real-life examples will be provided. For instance, a poultry processor using real-time data can automatically adjust processes on the production line, such as seasoning application and freezer loading, thus minimizing seasoning loss and optimizing freeze time. The ability to control processes based on real-time data is critical in optimizing process line performance.
Description: The presentation we will offer pros and cons of some shelf life extending technologies, such as heat treatment, microfiltration, bactofugation, etc., and cite examples. The presentation goal is to demonstrate how aseptic packaging/processing represents a unique opportunity for manufactures in the healthy food/beverage category. The presentation will provide show-goers the opportunity to review tests and the performance of aseptic technology across a wide range of pH levels, from dairy to juice to soy and other grain-based products.
Description: Ensuring the safety and integrity of container contents, as well as the people handling them, is an ongoing concern for chemical companies. Environmental factors are also coming into play, and chemical suppliers and their customers are seeing a dramatic shift toward closed-system dispensing and single-use containers made of recyclable materials. In this presentation, the audience will learn the following: 1) Industry trends in chemical dispensing systems, and the differences between “open” dispensing systems used today and “closed” systems of the future; 2) The benefits derived from adopting a closed-system approach: simplified logistics; reduced chemical waste, exposure and costs; enhanced worker safety; and minimized environmental impact; 3) How RFID technology can be used to enhance safety of dispensing systems.
Description: The packaging industry is hectic and constantly changing. There is only one way to make a difference in whether your business is thriving and profitable or struggling to keep up: Focus. At processors all across North America, the #1 cost of goods is resin, on average making up 50 to 75% of the cost of products; yet it’s rarely given the focus and attention it deserves. This enlightening presentation will open your eyes to the importance of a resin Focus and arm you with insider secrets that will help you find the savings to make a difference.
Description: Premature plugging and loss of volume are the major factors that result in poor print quality, slower press speeds and inconsistent densities, as well as coat weight. New advanced ceramic coatings with advanced release properties are now available that can resolve many of these issues, particularly in the area of higher like line count engravings.
Description: Printers will benefit from ink handling problems and how to solve them. By directing them to various methods, changing practices and looking at new ways to handle ink pumps, attendees will learn about why the human factor can derail the best laid plans. Plenty of examples will be included in the discussion.
Description: What if your existing production machinery were operating at optimized efficiency? That would mean you would have a minimum of scrap, exceptional quality, higher line speeds, reduced maintenance costs, no capital investment and ultimately higher profit. Many companies are realizing the benefits of aligning their assets. How about you?